Durable RFID printed fabric labels

ABSTRACT

Durable fabric RFID labels are provided for mounting on garments, fabrics and other fabric-containing items, the mounting and durability being before, during or after manufacturing and processing of the items. These labels are robust enough to withstand processing during manufacturing, while being capable of remaining on the item during inventory handling, merchandising and consumer use, including washing and drying. The durable labels include an RFID inlay, a face sheet overlying a first face of the RFID inlay, and a functional adhesive, such as a hot-melt adhesive, overlying a second face of the RFID inlay. The face sheet can be of printable material or have indicia or be a printed face sheet. The functional adhesive can be of a moisture-resistive type. The RFID inlay can be encased within a pocket of polymeric material. A polymeric sheet reinforcement layer can be adhered to and cover all or a portion of the RFID inlay.

BACKGROUND

Field of the Disclosure

The present subject matter relates to merchandise tracking tags. Moreparticularly, the present subject matter relates to assemblies employingwireless communication approaches such as radio frequency identification(“RFID”) technology useful in the context of merchandise production,processing and merchandising, which functions as a security and/oridentification tag in the form of an identification label, patch,decorative component or the like and especially suitable for clothing.

Description of Related Art

Devices incorporating wireless communication approaches including RFIDtechnology are widely used for a variety of different applications,including inventory control, tracking, guard and security systems. Suchsystems are well known in the retail industry, including in connectionwith clothing inventory control and security from theft and otherlosses.

RFID devices may have a variety of integrated components, among them anRFID chip containing data such as an identification code for the type ofproduct and/or product component, allowing for immediate electronicidentification and tracking of the exact piece of goods associated witha unique identification code. Other components include an antennaelectrically connected to the RFID chip, which is responsible fortransmitting signals to and/or receiving signals from another RFIDdevice, for example, an RFID reader system.

In one example, an RFID reader is associated with a point-of-salelocation or check-out counter of a retail facility and detects the chipin a tag associated with a piece of goods, which can include the stockkeeping unit (SKU) and register price of that item, as well as otherspecific identification indicia. In another example, an RFID-readabletag is attached to a piece of merchandise in a retail facility, whichtags are scanned using an RFID reader to keep proper count of theproduct inventory and/or to be used as a security measure functioning asa so-called guard tag.

RFID devices and antennas associated with or forming a part of suchdevices are well known. RFID chips or tags are well known and caninclude antennas suitable for particular intended uses. For example, anRFID device can include RFID chip, tag or strap in electroniccommunication with one or more dipole form antenna, which can featureradiating elements, such as on either side of the chip, tag or strap,with each radiating element configured to facilitate antennaperformance. In some circumstances, the antenna component takes the formof a hybrid loop-slot antenna or slot-loop hybrid antenna, at timesreferred to as a “sloop” antenna. A variation is a hybrid loop-apertureantenna, as generally known in the art.

Typical RFID devices of these general types are susceptible to damageand reduction or elimination of expected operability upon exposure tothe conditions of industrial processing of clothing, components or otheritems or products, particularly those made of fabric material. At timesherein, these are referred to as “fabric items.” Such susceptibility canbe experienced before, during and/or after manufacturing and processingand subsequent warehousing, merchandising, use and handling byconsumers. Included are industrial-type washing and other processing offabric clothing and/or components, including denim items, as well ashome laundering and wear-and-tear during consumer use. For example,traditional RFID tags, labels and printed fabric labels are not durablein apparel applications regarding home laundry wash or industrial-typewash cycles. In addition, RFID tags fail in many apparel manufacturingprocesses such as denim stone wash or enzyme bleaching.

SUMMARY

There are several aspects of the present subject matter which may beembodied separately or together in the devices and systems described andclaimed below. These aspects may be employed alone or in combinationwith other aspects of the subject matter described herein, and thedescription of these aspects together is not intended to preclude theuse of these aspects separately or the claiming of such aspectsseparately or in different combinations as may be set forth in theclaims appended hereto.

In one aspect or embodiment of the present disclosure, a durable orrobust merchandise tag, strap, patch, label or the like, at timesreferenced herein as a “durable label,” is of enhanced durability and isespecially useful for a variety of different applications, includinginventory control, tracking before, during and after manufacturing andprocessing, and consumer use, as well as in connection with guard andsecurity systems.

In another aspect or embodiment, a durable label has an RFID inlay, witha face sheet overlying one face of the RFID inlay, the face sheet beingprintable material or the face sheet being pre-printed. A functionaladhesive, such as a hot melt adhesive, overlies another face of the RFIDinlay, with a release sheet positioned over the functional adhesive. Thedurable label further has one, two or three of the following features:(1) the functional adhesive is a moisture resistive adhesive; (2) theRFID inlay is encased within a pocket of polymeric material; and/or (3)a polymeric reinforcement layer is adhered to and covers all or some ofthe RFID inlay.

In a further aspect or embodiment, a durable label has an RFID inlay,with a face sheet overlying one face of the RFID inlay, the face sheetbeing printable material or the face sheet being pre-printed, and with afunctional adhesive overlying another face of the RFID inlay. Thefunctional adhesive is a moisture-resistive adhesive which in oneembodiment is curing reactive. For example, the functional adhesive canbe a one-component polyurethane-based adhesive.

In an additional aspect or embodiment of this disclosure, a durablelabel has an RFID inlay, with a face sheet overlying one face of theRFID inlay, the face sheet being printable material or the face sheetbeing pre-printed, and with a functional adhesive overlying the otherface of the RFID inlay. The durable label is configured and formulatedto be secured to a fabric item and further has one, two or three of thefollowing features: (1) the functional adhesive is a moisture-resistiveadhesive; (2) the RFID inlay is encased within a pocket of polymericmaterial; and/or (3) a polymeric reinforcement layer is adhered to andcovers some or all of the RFID inlay.

In yet an added aspect or embodiment of the present disclosure, adurable label is secured to a fabric item, with the durable label ofthis combination having an RFID inlay. A face sheet overlies one face ofthe RFID inlay, with the face sheet being printable material or the facesheet being pre-printed, and with a functional adhesive overlying theother face of the RFID inlay. The durable label of the combinationfurther has one, two or three of the following features: (1) thefunctional adhesive is a moisture-resistive adhesive; (2) the RFID inlayis encased within a pocket of polymeric material; and/or (3) a polymericreinforcement layer is adhered to and covers all or some of the RFIDinlay.

In accordance with a further aspect or embodiment, a durable label issecured to a fabric item, with the durable label of this combinationhaving an RFID inlay. A face sheet overlies one face of the RFID inlay,with the face sheet being printable material or the face sheet beingpre-printed, and with a functional adhesive overlying another face ofthe RFID inlay. The durable label of the combination is secured to thefabric item by functional adhesive that is a moisture-resistiveadhesive. For example, the functional adhesive can be a one-componentpolyurethane-based adhesive.

Under a further aspect or embodiment, a durable label is secured to afabric item, with the durable label of this combination having an RFIDinlay. A face sheet overlies one face of the RFID inlay, with the facesheet being printable material or the face sheet being pre-printed, andwith a functional adhesive overlying another face of the RFID inlay ofthis durable label of the combination, which RFID inlay is encasedwithin a pocket of polymeric material.

In an added aspect or embodiment of the present disclosure, a durablelabel is secured to a fabric item, with the durable label of thiscombination having an RFID inlay. A face sheet overlies one face of theRFID inlay, with the face sheet being printable material or the facesheet being pre-printed with selected indicia for the particular fabricitem. A polymeric reinforcement layer is adhered to and covers some orall of the RFID inlay, with a typical RFID inlay including a chip, anantenna, and integrated circuitry therefor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a first label constructionembodiment according to the present disclosure;

FIG. 1A is a schematic illustration of a second label constructionembodiment according to the present disclosure;

FIG. 1B is a schematic illustration of a third label constructionembodiment according to the present disclosure;

FIG. 1C is a schematic illustration of the embodiment of FIG. 1, furtherincluding a fabric item;

FIG. 1D is a schematic illustration of the embodiment of FIG. 1A,further including a fabric item;

FIG. 1E is a schematic illustration of the embodiment of FIG. 1B,further including a fabric item;

FIG. 2 is a schematic illustration of an embodiment of a printed fabriclabel according to the present disclosure;

FIG. 2A is a schematic illustration of an embodiment of a printed fabriclabel of a “smart face” type according to the present disclosure;

FIG. 2B is a schematic illustration of the embodiment of FIG. 2, furtherincluding a fabric item;

FIG. 2C is a schematic illustration of the embodiment of FIG. 2A,further including a fabric item;

FIG. 3 is a schematic illustration of a printed fabric label includingan RFID encapsulation or pocket feature according to a furtherembodiment of the present disclosure;

FIG. 3A is a schematic illustration of an RFID encapsulated or pocketfeature of a sew-in pocket feature according to the present disclosure;

FIG. 3B is a schematic illustration of the embodiment of FIG. 3, furtherincluding a fabric item;

FIG. 3C is a schematic illustration of the embodiment of FIG. 3A,further including a fabric item;

FIG. 4 is a schematic illustration of a printed fabric label including areinforcement layer for the RFID inlay according to a further embodimentof the present disclosure;

FIG. 4A is a schematic illustration of an embodiment of the presentdisclosure including reinforcement adhesive-laminated to the RFID inlay;

FIG. 4B is a schematic illustration of the embodiment of FIG. 4, furtherincluding a fabric item; and

FIG. 4C is a schematic illustration of the embodiment of FIG. 4A,further including a fabric item.

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. Therefore, specific details disclosed herein are not to beinterpreted as limiting, but merely as a basis for the claims and as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention in virtually any appropriate manner.

The durable labels and RFID fabric labels disclosed herein are bothrobust and washable and are of relatively low thickness and exhibit adegree of flexibility suitable for clothing and other fabric item uses.Having these properties, the durable labels are especially suitable foruse as labels, patches, tags, decorative overlays, printed fabric labelsand the like for fabric items including garments and other wearables.Garments and other fabric items can be subjected to processing,including washing, so-called “stone washing” for denim and the like,and/or chemical treatment such as enzyme bleaching, during theirprocessing or production. When thus used, the durable labels of thisdisclosure are robust and durable, including with respect to potentialbreakage of the RFID inlay components such as an antenna conductor.

The RFID devices of the present disclosure are capable of withstandingwashing and other processes without having to incorporate material thatadds excessive thickness, which would make the tags stiffer thandesired, also impacting garment wearability. For example, this form ofRFID label is well suited to inclusion in all forms of patches or otherheat-applied, sonic-applied or adhesive-applied structures. The RFIDlabels described herein are useful as printed fabric labels or otherembellishments such as decorative components that are intended to staywith the garment or other fabric items during all stages of manufacture,merchandising and consumer use. This allows, inter alia, improvedprocessing and/or inventory control that increases production andmerchandising efficiency while presenting a durable, attractive andminimally intrusive labeling approach.

It will be appreciated that the present RFID labels provide enhancedprotection against chemical and mechanical damage when incorporated ontoor into fabric items, such as garments, clothing or other fabric orsheet stock items. Typical examples of processes include washing,dyeing, stone washing, bleaching and drying, whether duringmanufacturing or by users of the fabric items. These types of processescan be part of the manufacturing process, and some or all may occur whenthe fabric items are in use.

The present RFID labels address a number of problems. One problem isdisruption of the antenna conductor by breakage, cracking, tearing orattack by water or other chemical substance to which they are exposedduring manufacturing, processing and/or consumer use. Other problemsthat are addressed are concerns about the disruption of the jointbetween the antenna and the RFID chip. In some cases, a strap orinterposer is used, and the present approach addresses the problem ofdamage to the connection between the RFID chip and the strap, as well asdamage to the connection between the strap and antenna joints.Furthermore, the present approach addresses concerns of physical damageto the RFID chip, such as cracking or crushing of the silicon structure.The various structures disclosed herein are effective in reducing theabove-noted problems, concerns and potential damage.

The present disclosure involves three levels of enhancement to standardRFID products to pass all or some of the difficulties encountered duringproblem wash cycles and other harsh processing. A first enhancement isinclusion of a lamination adhesive that will adhere together layers ofan RFID device or fabric item such as a printed fabric label for thelife of garment processing, industrial wash and home wash cycles, dryingcycles and other processing for the life of the garment (traditionallyat least 25 wash cycles). A second enhancement involves encapsulation ofthe RFID elements into a water-proof flexible pouch to protect theantenna and chip from corrosive detergents, for example. A thirdenhancement involves reinforcement of the UHF/HF/NFC chip or strapattachment from excessive mechanical stress. Utilization of eachenhancement separately, or in any combination of two enhancements, orall enhancements together provides the required level of durability forthe aforementioned manufacturing, processing, merchandising and customerapplications.

These advantages are achieved without modifying standard RFID inlays toaddress these challenges. In a general sense, which one or ones of thethree enhancements are to be applied to provide a particular durablelabel or fabric item can be expected to vary depending on the severityof the conditions expected for the particular inlay and product or itemwithin which is it associated or to which it is secured. Particularapplication for the technology of this disclosure is for flexibleprinted labels (or PFL's), but application also is suitable for standardlabels and tags as well.

FIG. 1 illustrates an RFID label, generally designated as 21, whichincludes an RFID inlay with RFID chip 22 and antenna 23, typically alsohaving integrated circuitry and various adhesive connections that areaffected by liquids and mechanical stresses, such as bending andcompression. The RFID chip 23 and antenna are electrically coupled byintegrated circuitry, such as by way of respective points of contact, inaccordance with construction details and materials as known in the art.RFID chips can be variously configured in accordance with the particularapplication, for example including an integrated circuit for controllingRF communication and other functions of the RFID device.

The traditional RFID tags and labels are typically used in static simpleenvironmental conditions. That said, apparel and industrial trackingbusiness and customers utilizing RFID technology at times requireexpanding the technology upstream and downstream in the supply chain inaddition to traditional retail store or shipping inventory countingapplications. For example, RFID capabilities can be required at thestart of a production cycle, and/or they can continue to operate as longas the garment may be utilized in its life cycle, such as through atleast 25 wash and dry cycles. These uses add stresses and environmentalconditions that will degrade the RFID inlay or cause the product to failbefore its intended purposes have been completed.

RFID label 21 illustrates a “two-pass” label construction having anoutside layer, or face sheet 25, that is printable or printed upon withindicia such as marketing messaging, product or item identification,manufacturing and materials disclosure information, sizing, decoration,logo, and so forth. This sheet typically will be a material in thefabric genre, for example polymeric-including or polymeric-based fabric,such as woven polyester, woven nylon, filled and blended fabric, and thelike. RFID label 21 a of FIG. 1A and RFID label 21 b of FIG. 1B alsoinclude this face sheet 25.

Further, each of FIG. 1, FIG. 1A and FIG. 1B illustrate a functionaladhesive 26 protected by a release liner 27 that is removed prior toaffixing the RFID label 21, 21 a, 21 b to a garment, fabric item orother product or component to which the durable label is to be secured(as in FIG. 1C, FIG. 1D and FIG. 1E). The RFID label 21 of FIG. 1 has asecond-pass component that is a layer of polymer material on either sideof the RFID inlay, shown as layers 28 and 28′, which can be twoindividual or separate pieces, such as two sheets, or alternatively asingle sheet forming both layers. These polymer layers typically aremade of a polyester, for example polyethylene terephthalate (or PET).For clarity and ease of understanding, FIG. 1, and all drawings of thisdisclosure, show their various layers and/or components separated;however, it will be appreciated by those of ordinary skill that the RFIDlabel will be an assembly of these sheets and layers in directengagement with each adjacent layer or sheet, typically joined byfollowing lamination procedures using lamination equipment such as byway of nip roller action.

FIG. 1A illustrates another embodiment of an RFID label 21 a, thisemploying a low-cost LCSF single pass approach, wherein the RFID inlaydirectly engages the face sheet 25 and the functional adhesive 26. Theantenna assembly used for this LCSF single pass approach can be formedof aluminum, rather than including any polyester (e.g. PET), such as alayer corresponding to layers 28, 28′ of the FIG. 1 embodiment.

FIG. 1B illustrates another embodiment of an RFID label 21 b, thisemploying a DCSF single pass approach, wherein the RFID inlay directlyengages the face sheet 25, but not the functional adhesive 26. Theantenna used for this DCSF single pass approach includes a thin film ofpolyester, e.g. PET, (not shown) as part of the antenna raw material(along with aluminum) and is included in the antenna shape. Rather thandirectly engaging the functional adhesive 26 (as in the embodiment ofFIG. 1A), a paper substrate 29 may be positioned between the antenna 23and the functional adhesive 26.

RFID labels 21, 21 a and 21 b each constitute printed fabric labels thatare laminated and include a functional adhesive 26 that is a standardfunctional adhesive, which in one embodiment contemplated by the presentinvention is a type of hot melt adhesive, being a moisture-resistiveadhesive. The present invention contemplates that the moisture resistiveadhesive in one embodiment may be curing-reactive, but is not limited tobeing curing-reactive. Typically, hot melt adhesives begin to delaminateafter ten to fifteen wash cycles. Functional adhesives are characterizedby being solid systems that do not require either moisture forapplication or moisture removal for setting. According to the presentdisclosure, the functional adhesive component is of a type falling inthe family of one-component, moisture-curing reactive polyurethanefunctional adhesives. Such functional adhesives require humidity orwater vapor to initiate the reaction of the chemical composites of theadhesive in order to cure. These achieve a durability in excess ofthirty wash-and-dry cycles. One hot melt adhesive contemplated by thepresent invention is moisture-curing, has a higher humidity increasescuring speed, and the adhesive prior to use is, in one embodiment,protected against humidity exposure. With these types of adhesives,linkage to the woven fabric fibers of the face material with theadhesive achieves the cross-linkage providing the permanent bond effectthat is characteristic of the first enhancement of the presentdisclosure.

FIG. 1C is a schematic illustration of the embodiment of FIG. 1 whencombined with a fabric item 30 associated with the RFID label 21. Thisshows the combination of the RFID label secured to the fabric item. Therelease liner 27 of the corresponding label is omitted from FIG. 1C,same having been removed before the functional adhesive 26 adhesivelysecures the durable RFID label 21 to the fabric item 30. As with otherviews in this disclosure, the functional adhesive is shown separatedfrom the fabric item for purposes of drawing clarity, and it will beunderstood there is no separation when the durable RFID label isadhesively secured to the fabric item.

FIG. 1D is a schematic illustration of the embodiment of FIG. 1A whencombined with a fabric item 30 associated with the RFID label 21 a. Thisshows the combination of the RFID label secured to the fabric item. Therelease liner 27 of the corresponding label is omitted from FIG. 1D,same having been removed before the functional adhesive 26 adhesivelysecures the durable RFID label 21 a to the fabric item 30. As with otherviews in this disclosure, the functional adhesive is shown separatedfrom the fabric item for purposes of drawing clarity, and it will beunderstood there is no separation when the durable RFID label isadhesively secured to the fabric item.

FIG. 1E is a schematic illustration of the embodiment of FIG. 1B whencombined with a fabric item 30 associated with the RFID label 21 b. Thisshows the combination of the RFID label secured to the fabric item. Therelease liner 27 of the corresponding label is omitted from FIG. 1E,same having been removed before the functional adhesive 26 adhesivelysecures the durable RFID label 21 b to the fabric item 30. As with otherviews in this disclosure, the functional adhesive is shown separatedfrom the fabric item for purposes of drawing clarity, and it will beunderstood there is no separation when the durable RFID label isadhesively secured to the fabric item.

Other embodiments of durable RFID labels are illustrated in FIG. 2 andFIG. 2A, each in combination with a fabric item being shown in FIG. 2Band FIG. 2C, respectively. FIG. 2 shows an RFID label, generallydesignated as 31. An RFID inlay having an RFID chip 32 and antenna 33 asgenerally discussed herein, with face sheets 35, 35′ and a lamination orfunctional adhesive 36 as discussed regarding FIG. 1 between face sheet35′ and a polymer layer 38 are included in this embodiment. The polymerlayer 38 typically is a polyester or contains a polyester, such as PET,providing what can be identified in the art as a PET-based printedfabric label embodiment. FIG. 2A illustrates a so-called “smart face”printed fabric label embodiment which generally follows the FIG. 2embodiment, but does not contain any polymer/polyester/PET type layer 38of FIG. 2.

FIG. 2B is a schematic illustration of the durable RFID label embodimentof FIG. 2 when combined with a fabric item 39 associated with the RFIDlabel 31. For this combination, the RFID label is shown secured to thefabric item. Securement in this context can include attachment of theRFID label to the garment by adhesive, sew-in technology, placement ofbrads or other approaches, whether the attachment is throughout theentire extent of a surface of the RFID label, is along all or a portionof the perimeter of the surface of the RFID label, or results in tackingof the RFID label to the fabric item. Which securement option isutilized, and whether or not the securement is intended to be permanentor intentionally removable, will depend on the fabric item and thedesignated or intended function of the RFID label during manufacture,marketing and consumer use. As with other views in this disclosure, theface sheet is shown separated from the fabric item for purposes ofdrawing clarity, and it will be understood there is no separation whenthe durable RFID label is secured to the fabric item.

FIG. 2C is a schematic illustration of the durable RFID label embodimentof FIG. 2A when combined with a fabric item 39. For this combination,the RFID label is shown secured to the fabric item, securement being asdescribed with respect to the FIG. 2B RFID label and fabric itemcombination.

FIGS. 3 and 3A illustrate embodiments that include the polymeric pocketencasement enhancement feature. In connection with the presentdisclosure, prevention of liquid ingression to the RFID elements is acharacteristic of the present disclosure and also is a characteristic ofthese embodiments, to assure enhanced life and continued acceptableperformance of garments or other fabric items when subjected to thetypes of conditions discussed herein. Traditional adhesives that are notaccording to the present disclosure and traditional lamination methodsdo not provide the bonding protection from the temperature andmechanical stresses that would be typically encountered by fabric itemsin the category of the present disclosure, for example several up to 60°C. wash cycles and several up to 90° C. dry cycles. FIG. 3 shows an RFIDlabel, generally designated as 41, while FIG. 3A shows an RFID label,generally designated as 41 a.

In accordance with these FIG. 3 and FIG. 3A embodiments, effectiveencasement of the RFID inlay within a waterproof pocket is achievedthrough permanent melt bonding, sealing or welding of two layers ofthermoplastic material, referenced herein as pocket encasement layers44, 44′. Bonding of such layers together, with the RFID componentspermanently encased inside, protects against ingression of moisture.These encasements typically are most efficiently prepared by processingin roll-to-roll form on a continuous basis, incorporating roll nipaction, in which waterproof pockets can then be delivered as die cutpackets to be inserted into the lamination process as discussed hereinfor insertion into or combining as pockets with apparel or other fabricitems. For example, in a roll-to-roll manufacturing process, a layer ofthe thermoplastic material has the RFID inlays inserted across and downthe sheet web and then proceeds with forming a final laminate of thesecond layer to the first layer, and then die cuts out the finalwaterproof pockets with a steel rule die cutter. Specific conditions,such as temperature, pressure and residence time in the laminating nipand heating rollers, for example, will vary depending on the particularthermoplastic material or materials forming the pocket.

Included in such thermoplastic materials are thermoplastic polyurethane(TPU), polyethylene terephthalate glycol (PETG), polyethyleneterephthalate (PET), ethylene vinyl acetate (EVA), high-densitypolyethylene (HDPE), blends thereof, multi-layered components thereof,and combinations thereof. One specific example of a blended combinationis EVA and HDPE. Specific examples of multi-layered embodiments includebondable films such as combinations of PET-TPU and/or PET-EVA.Compatibility for blending and/or multi-layering, or compatibility ofcombinations of differing ones of these thermoplastic materials asbetween the layers will generally be appreciated in the art. Suchcompatibility takes into consideration the degree of thermodynamicmiscibility of the differing materials.

With further reference to the waterproof pocket embodiments, such as thedurable labels, generally designated as 41, 41 a in FIG. 3 and FIG. 3A,respectively, have an RFID inlay with an RFID chip 42 and antenna 43 asgenerally discussed herein, with face sheets 45, 45′, together with (inthe embodiment of FIG. 3) a lamination or functional adhesive 46 asdiscussed regarding FIG. 1 and other embodiments. With FIG. 3 and FIG.3A, the RFID inlay is within a pocket encasement having layers 44, 44′,which can be two individual or separate pieces, such as two sheets, oralternatively a single sheet forming both layers. In the FIG. 3embodiment, these thermoplastic pocket encasement layers are betweenface sheets 45, 45′, and the functional or lamination adhesive 46 joinsthe thermoplastic pocket to the face sheet or sheets. Further, theadhesive can join the face sheets 45, 45′ together as desired. FIG. 3Aillustrates an embodiment where the RFID inlay is fused between thethermoplastic layers 44, 44′ and includes a layer 48 of polymericmaterial such as PET overlying one or both surfaces of the RFID inlay.This embodiment can be especially suitable for approaches where thepocket encasement is sewn into the fabric item, such as under a patch orinside a garment seam.

FIG. 3B is a schematic illustration of the durable RFID label embodimentof FIG. 3 when combined with a fabric item 49 associated with thedurable RFID label 41. For this combination, the RFID label is shownsecured to the fabric item. Securement in this context can includeattachment of the RFID label to the garment by adhesive, sew-intechnology, placement of brads or other approaches, whether theattachment is throughout the entire extent of a surface of the RFIDlabel, is along all or a portion of the perimeter of the surface of theRFID label, or results in tacking of the RFID label to the fabric item.Which securement option is utilized, and whether or not the securementis intended to be permanent or intentionally removable, will depend onthe fabric item and the designated or intended function of the RFIDlabel during manufacture, marketing and consumer use. As with otherviews in this disclosure, the face sheet is shown separated from thefabric item for purposes of drawing clarity, and it will be understoodthere is no separation when the durable RFID label is secured to thefabric item.

FIG. 3C is a schematic illustration of the durable RFID label embodimentof FIG. 3A when combined with a fabric item 49. For this combination,the RFID label is shown secured to the fabric item, securement being asdescribed with respect to the FIG. 3B RFID label and fabric itemcombination.

Durability reinforcement enhancement embodiments of the presentdisclosure assure a life for the durable label of the fabric items for aminimum of twenty-five wash-and-dry cycles and their attendantmechanical bending and stretch-and-compression actions. Rigidreinforcement of the RFID inlay is, for most applications for fabricitems, unacceptable for apparel “look” and for physical “feel”requirements. Previously proposed or practiced highly flexibleover-laminates provide minimal protection. The embodiments hereofincluding durability reinforcement enhancement of these embodiments orincluding when combined with other enhancement embodiments as describedherein provide necessary protection of RFID functionality, for theintended life of the fabric item, such as a garment, piece of clothing,accessory or non-clothing fabric item. Embodiments relevant to same areillustrated in FIG. 4 and FIG. 4A. These particular embodiments areshown with an option of a pocket encasement structure as generallydiscussed with respect to FIG. 3 and FIG. 3A.

This durability reinforcement enhancement feature provides the RFIDlabels, generally designated as 51 and 51 a in FIGS. 4 and 4A,respectively, by an approach that directly protects the RFID chip 52,and key areas of the RFID antenna 53, or other components associatedwith the RFID inlay, as desired. Achieving this durability reinforcementenhancement includes a layer 58 of polymeric material such as PEToverlying one or both surfaces of the RFID inlay. Specifically, in theFIG. 4 and FIG. 4A embodiments, a resistive functional adhesive 56,which may be of the type discussed herein with respect to FIG. 1 andother embodiments, secures the polymeric sheet layer 58 to at least oneface of the RFID inlay to fully cover the RFID chip 52. For example, thelayer 58 can be in the form of a disc to extend beyond the perimeter ofa generally circular RFID chip. In FIG. 4A, a further layer 58′ ofpolymeric material such as PET overlies an opposite face of the fullRFID inlay, including both the RFID chip and RFID antenna.

Concerning the pocket encasement structure shown as a component in eachof FIG. 4 and FIG. 4A, the RFID inlay is within a pocket encasementhaving layers 54, 54′, which can be two individual or separate pieces,such as two sheets, or alternatively a single sheet forming both layers.In the FIG. 4 embodiment, these thermoplastic pocket encasement layersare between face sheets 55, 55′, and the functional or laminationadhesive joins the thermoplastic pocket to the face sheet or sheets, andcan join the face sheets 55, 55′ together as desired. FIG. 4Aillustrates an embodiment where the RFID inlay and its associateddurability reinforcement enhancement that includes layers 58, 58′ ofpolymeric material fused between the thermoplastic layers 54, 54′.

FIG. 4 is an embodiment of reinforced thermoplastic polyurethane (TPU)as a durable printed fabric label with a single reinforcing polymerlayer as discussed herein (e.g. PET) disc. FIG. 4A is an embodiment ofreinforced thermoplastic polyurethane as a durable printed fabric labelwith a pair of reinforcing polymer layer (e.g. PET) discs. The discreinforcement may be adhesive-laminated to the RFID inlay and antenna,as in the embodiment of FIG. 4 or, as in the FIG. 4A embodiment, theRFID inlay may be heat fused between two TPU layers.

FIG. 4B is a schematic illustration of the durable RFID label embodimentof FIG. 4 when combined with a fabric item 59 associated with thedurable RFID label 51. For this combination, the RFID label is shownsecured to the fabric item. Securement in this context can includeattachment of the RFID label to the garment by adhesive, sew-intechnology, placement of brads or other approaches, whether theattachment is throughout the entire extent of a surface of the RFIDlabel, is along all or a portion of the perimeter of the surface of theRFID label, or results in tacking of the RFID label to the fabric item.Which securement option is utilized, and whether or not the securementis intended to be permanent or intentionally removable, will depend onthe fabric item and the designated or intended function of the RFIDlabel during manufacture, marketing and consumer use. As with otherviews in this disclosure, the face sheet is shown separated from thefabric item for purposes of drawing clarity, and it will be understoodthere is no separation when the durable RFID label is secured to thefabric item.

FIG. 4C is a schematic illustration of the durable RFID label embodimentof FIG. 4A when combined with a fabric item 59 associated with the RFIDlabel 51 a. For this combination, the RFID label is shown secured to thefabric item, securement being as described with respect to the FIG. 3BRFID label and fabric item combination.

It will be appreciated, with the durability reinforcement enhancementfeature such as illustrated in FIGS. 4 and 4A, coverage of the RFIDinlay with polymeric material layers 58, 58′ is strategically designedfrom, for example, simple spot coverage to full coverage of the RFIDinlay or partial coverage thereof to achieve desired results for variouspossible RFID inlay designs, configurations and structures. For example,the strategic design will vary among the various radiofrequency (RF)frequencies of UHF, HF or NFC. Also, thickness of the polymeric materiallayers 58, 58′ can vary depending on the specifics of an RFID inlay andthe intended application. Typical thickness ranges are between about0.004 inch and about 0.04 inch, between about 0.005 inch and about 0.03inch, between about 0.007 inch and about 0.02 inch, or between about0.008 inch and about 0.01 inch.

Other embodiments, besides those illustrated herein, may also beemployed without departing from the scope of the present disclosure. Forexample, other means for attaching the RFID label to a garment or otherfabric item or otherwise bendable material can be employed, such assewing, brads or other connection mechanisms. Further, RFID inlayconfiguration variations may be employed. Relative sizes of layers canvary in accordance with intended uses, including variation in area offace sheets so as to extend fully beyond interior components andvariation in area of application of the functional or laminationadhesive to secure multiple components together.

It will be understood that the embodiments described above areillustrative of some of the applications of the principles of thepresent subject matter. Numerous modifications may be made by thoseskilled in the art without departing from the spirit and scope of theclaimed subject matter, including those combinations of features thatare individually disclosed or claimed herein. For these reasons, thescope hereof is not limited to the above description but is as set forthin the following claims, and it is understood that claims may bedirected to the features hereof, including as combinations of featuresthat are individually disclosed or claimed herein.

The invention claimed is:
 1. A combination of a durable label secured to a fabric item, comprising: a label comprising a radio frequency identification (RFID) inlay having a first face and a second face; a thermoplastic polyurethane polymeric sheet reinforcement layer adhered to and covering the first face of the RFID inlay or a portion of the RFID inlay; a face sheet overlying the polymeric reinforcement layer; and a functional adhesive overlying the second face of the RFID inlay; and the fabric item durably secured to the label via the functional adhesive.
 2. The durable label of claim 1, further including a release layer overlying the functional adhesive.
 3. The durable label in accordance with claim 1, wherein the face sheet is of a printable material or has an exposed face with indicia thereon.
 4. The durable label in accordance with claim 1, wherein the RFID inlay is encased within a pocket of polymeric material.
 5. The durable label in accordance with claim 1, where the functional adhesive is a type of hot melt adhesive.
 6. The durable label of claim 5, where the functional adhesive is a one-component polyurethane-based moisture- resistive adhesive.
 7. The durable label of claim 6, where the moisture resistive adhesive is curing-reactive.
 8. A combination of a durable label secured to a fabric item, comprising: a label comprising a radio frequency identification (RFID) inlay having a first face and a second face; a polymeric sheet reinforcement layer adhered to and covering the RFID inlay or a portion of the RFID inlay, the RFID inlay and reinforcement layer being encased within a pocket of polymeric material; a face sheet overlying the first face of the RFID inlay; and functional adhesive being a one-component polyurethane-based moisture-resistive adhesive; and the fabric item durably secured to the label via the functional adhesive.
 9. The durable label of claim 8, further including a release layer overlying the functional adhesive.
 10. The durable label in accordance with claim 8, wherein the polymeric material is selected from the group consisting of thermoplastic polyurethane, polyethylene terephthalate, polyethylene terephthalate glycol, ethylene vinyl acetate, high-density polyethylene, blends thereof, multi-layered components thereof, and combinations thereof.
 11. The durable label in accordance with claim 8, where the moisture resistive adhesive is curing-reactive.
 12. The durable label in accordance with claim 8, wherein the RFID inlay is encased within a pocket of polymeric material.
 13. The durable label of claim 8, where the thickness of the polymeric material ranges from about 0.0004 inch and 0.04 inch between about 0.005 inch and about 0.03 inch, between about 0.007 inch and about 0.02 inch, or between about 0.008 inch and about 0.01 inch. 